Sorbent compositions and methods for the removal of contaminants from a gas stream

ABSTRACT

A sorbent composition for the sequestration of mercury from a gas stream, a method for sequestering mercury from a gas stream and a method for the manufacture of a sorbent composition. The sorbent composition includes a highly porous particulate sorbent and at least two additive components, namely a non-halogen metal compound comprising a metal cation and an inorganic sulfur-containing compound, where at least a portion of the sulfur in the sulfur-containing compound has an oxidation state of equal to or less than +4. The method includes injecting the highly porous particulate sorbent and the two additive components into a gas stream, either discretely or as a single sorbent composition, to sequester mercury in the particulate sorbent. The method has a high degree of efficacy for mercury removal without requiring the addition of halogens to the gas stream.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit under 35 USC § 119(e) as adivisional of U.S. patent application Ser. No. 16/418,975 filed May 21,2019, which claims priority to U.S. Provisional Patent Application No.62/674,467 filed on May 21, 2018, entitled “SORBENT COMPOSITIONS ANDMETHODS FOR THE REMOVAL OF CONTAMINANTS FROM A GAS STREAM.” Each of theforegoing applications is incorporated herein by reference in itsentirety.

FIELD

This disclosure relates to the field of sorbent compositions,particularly sorbent compositions that are useful for the removal andsequestration of contaminants such as mercury from a flue gas stream,and to methods for the removal of contaminants from a flue gas stream.

BACKGROUND

Mercury is known to be a highly toxic compound. Mercury exposure atappreciable levels can lead to adverse health effects for people of allages, including harm to the brain, heart, kidneys, lungs, and immunesystem. Although mercury is naturally occurring, most mercury emissionsresult from various human activities such as burning fossil fuels andother industrial processes.

One technology for mercury control from coal-fired power plants isactivated carbon injection (“ACP”). Activated carbon injection involvesthe injection of sorbents, typically including powder activated carbon(“PAC”), into the flue gas stream emitted by the boiler of a powerplant. Powder activated carbon is a porous carbonaceous material havinga high surface area, which exposes significant amounts of beneficialchemically functional and reactive sites and which creates highadsorptive potential for many compounds, including capturing mercuryfrom the flue gas. Activated carbon injection technology has shown thepotential to control mercury emissions in most coal-fired power plants,even those plants that may achieve some mercury control through controldevices designed for other pollutants, such as wet or dry scrubbers usedto control sulfur dioxide and acid gases.

The capture and removal of mercury from a boiler flue gas by activatedcarbon injection can be characterized by three primary steps, which mayoccur sequentially or simultaneously: (1) contact of the injectedsorbent particle, such as PAC, with the mercury species, which istypically present in very dilute concentrations in the flue gas (e.g.,<100 parts per billion); (2) oxidation of elemental mercury (i.e., Hg⁰),which is relatively inert and not easily adsorbed, into an oxidizedmercury species (e.g., Hg+ and Hg+²), which is more readily adsorbableand is significantly more soluble in an aqueous solubilizing medium suchas water; and (3) capture of the oxidized mercury species by the poresof the sorbent where it is held tightly (e.g., sequestered) withoutbeing released. Flue gas streams traverse the ductwork at very highvelocities, such as in excess of 25 feet/second. Therefore, onceinjected, the particulate sorbent composition must rapidly contact,oxidize and sequester the mercury. In some instances, the sorbent onlyhas a residence time of about 1 to 2 seconds in the flue gas.

Sorbent compositions for the sequestration of mercury often include ahalogen to facilitate oxidation of the elemental mercury, i.e., step (2)above. See, for example, U.S. Pat. No. 9,539,538 by Wong et al., whichis incorporated herein by reference in its entirety. In some cases thehalogen is present in the sorbent in concentrations of 10 wt. % or more.In other cases the halogen, such as bromine, is added separately fromthe sorbent as in U.S. Pat. No. 8,309,046 to Pollack et al. However, theaddition of halogens such as bromine to the flue gas stream may causecorrosion of treatment units. In addition, non-protective scales can beformed because of the presence of hydrobromic acid (HBr) in the fluegas. In addition to the corrosive effects of adding bromine into theflue gas stream, several other plant issues can also arise; bromineaccumulation in the wet scrubbers, deterioration of the fabrics in abaghouse, and the decrease of selenium capture within the plant's nativefly ash.

SUMMARY

While halogens are known to be effective for the oxidation of mercury toenhance sequestration by a particulate sorbent, e.g., by PAC, halogenscan be highly corrosive with respect to the equipment used in powerplants where carbonaceous materials are combusted, e.g., for powergeneration. Halogens may also contaminate the waste water dischargedfrom the power plant, and when combined with organic residual in thewater can lead to undesirable formation of trihalomethanes.

There is a need for sorbent compositions that can be injected into fluegas streams to effectively sequester contaminants such as mercury, whilereducing the problems associated with the use of halogens as an oxidant,e.g., for mercury.

In one embodiment, a sorbent composition for the capture of contaminantsfrom a gas stream is disclosed. The sorbent composition comprises aparticulate sorbent, a non-halogen metal compound comprising a metalcation, and an inorganic sulfur-containing compound, wherein at least aportion of the sulfur in the sulfur-containing compound has an oxidationstate of equal to or less than +4.

The foregoing sorbent composition may be subject to refinements,characterizations and/or additional features, which may be implementedalone or in any combination. As noted above, it is an advantage that thesorbent compositions disclosed herein can be effective for thesequestration of mercury, e.g. from a flue gas stream, without the needfor significant additions of halogens, e.g., of Br, Cl, F or I. In onerefinement, the sorbent composition comprises not greater than about 0.5wt. % halogens. In a further refinement, the sorbent compositioncomprises not greater than about 0.1 wt. % halogens. In yet a furtherrefinement, the sorbent composition comprises substantially no halogens.

In one characterization, the particulate sorbent is selected from thegroup consisting of alumina sorbents, silica sorbents andaluminosilicate sorbents. In another characterization, the particulatesorbent comprises a carbonaceous sorbent. In one refinement thecarbonaceous sorbent comprises activated carbon, and in a furtherrefinement, the activated carbon comprises powered activated carbon. Inanother refinement, the carbonaceous sorbent is derived from coal.

In another characterization, the particulate sorbent has a fine particlesize, and in one refinement, the particulate sorbent has a medianparticle size of not greater than about 50 μm. In a further refinement,the sorbent has a median particle size of not greater than about 30 μm,and in yet a further refinement, the particulate sorbent has a medianparticle size of not greater than about 20 μm. In anothercharacterization, the particulate sorbent has a median particle size ofat least about 2 μm, and in yet a further refinement the particulatesorbent has a median particle size of at least about 5 μm.

In another characterization, the particulate sorbent has a sum ofmicropore volume, mesopore volume and macropore volume of at least about0.2 cc/g. In another characterization, the particulate sorbent has asurface area of at least about 350 m²/g.

In another characterization, the metal cation is selected from the groupconsisting of cations of Fe, Cu, V, Mn, Co, Ni and Zn. In onerefinement, the metal cation selected from the cations of Fe, Cu, V, Mn,Co, Ni and Zn has an oxidation state of +2 or +3, and in a furtherrefinement has an oxidation state of +3. In another refinement, themetal cation is selected from the cations of Fe and Cu.

In yet another characterization, the non-halogen metal compound isselected from the group consisting of a sulfate compound and a nitratecompound. In one refinement, the non-halogen metal compound is selectedfrom the group consisting of Fe2(SQ4)3, FeSQ4 and CuSO4. In yet afurther refinement, the non-halogen metal compound is Fe2(SQ4)3.

In another characterization, the sorbent composition comprises at leastabout 0.1 wt. % of the metal cation. In one refinement, the sorbentcomposition comprises at least about 0.5 wt. % of the metal cation. Inanother characterization, the sorbent composition comprises not greaterthan about 20 wt. % of the metal cation, and in one refinement thesorbent composition comprises not greater than about 5 wt. % of themetal cation.

In another refinement, the sulfur in the sulfur-containing compound is aconstituent of a sulfur-containing anion. In one characterization, thesulfur-containing anion is selected from the group consisting ofthiocyanate (SCN)¹—, thiosulfate (S2O3)²—, tetrathionate (S4O6)²- andpolythionate (SQ3-Sn-SQ3)²—. In one refinement the sulfur-containinganion is thiocyanate (SCN)¹—, and in a further refinement, thesulfur-containing compound is selected from the group consisting ofsodium thiocyanate (NaSCN) and ammonium thiocyanate (NH4SCN). In anotherrefinement, the sulfur-containing anion is thiosulfate (S2O3)²—, and ina further refinement the sulfur-containing compound is selected from thegroup consisting of sodium thiosulfate (Na2S2Q3) and ammoniumthiosulfate ((NH4)₂S2O3).

In another characterization, the sorbent composition comprises at leastabout 0.1 wt. % sulfur from the sulfur-containing compound, and in onerefinement the sorbent composition comprises at least about 1.0 wt. %sulfur from the sulfur-containing compound. In another characterization,the sorbent composition comprises not greater than about 25 wt. % sulfurfrom the sulfur-containing compound, and in further refinement thesorbent composition comprises not greater than about 10 wt. % sulfurfrom the sulfur-containing compound.

In yet another characterization, the sorbent composition comprisesfree-flowing particles of the particulate sorbent, e.g., particles thatare capable of being injected into a flue gas stream and subsequentlycollected in a particle collection device. In another characterization,at least one of the non-halogen metal compound and the inorganicsulfur-containing compound comprise particulates that are admixed withthe particulate sorbent. In another characterization, at least one ofthe non-halogen metal compound and the inorganic sulfur-containingcompound are coated onto the particulate sorbent.

In another embodiment, a method for the treatment of a gas stream tocapture contaminants from the gas stream is disclosed. The methodincludes the steps of contacting the flue gas stream with a particulatesorbent to disperse the particulate sorbent within the flue gas,contacting the flue gas stream with a non-halogen metal compoundcomprising a metal cation, contacting the flue gas stream an inorganicsulfur-containing compound, wherein at least a portion of the sulfur inthe sulfur-containing compound has an oxidation state of equal to orless than +4, and separating the particulate sorbent from the flue gasstream.

The foregoing method may be subject to characterizations, refinementsand/or additional steps, which may be implemented alone or in anycombination. In one characterization, the contacting steps are carriedout by contacting the flue gas stream with a sorbent compositioncomprising the particulate sorbent, the non-halogen metal compound andthe inorganic sulfur-containing compound. For example, the sorbentcomposition may be a sorbent composition as disclosed herein. In onerefinement, the sorbent composition comprises not greater than about 0.5wt. % halogens, and in another refinement the sorbent compositioncomprises not greater than about 0.1 wt. % halogens. In yet anotherrefinement, the sorbent composition comprises substantially no halogens.In another refinement, the sorbent composition is in the form offree-flowing particulates, and the contacting steps comprise injectingthe free-flowing sorbent composition particulates into the flue gasstream.

In another characterization, the step of contacting the flue gas streamwith a particulate sorbent comprises injecting the particulate sorbentinto the flue gas stream. In one refinement, the step of contacting theflue gas stream with the inorganic sulfur-containing compound comprisesinjecting the inorganic sulfur-containing compound into the flue gasstream. In another refinement, the inorganic sulfur-containing compoundis injected into the flue gas stream as a discrete component, i.e., theinorganic sulfur-containing compound is not intimately associated withthe particulate sorbent. In another refinement, the step of contactingthe flue gas stream with the non-halogen metal compound comprisesinjecting the non-halogen metal compound into the flue gas stream. Inone particular refinement, the non-halogen metal compound is injectedinto the flue gas stream as a discrete component.

In another characterization, the gas stream is a flue gas streamemanating from a boiler. In one refinement, the gas stream is a flue gasstream emanating from a coal-fired boiler. In yet another refinement,contaminants comprise mercury.

In another embodiment, a method for the manufacture of a sorbentcomposition is disclosed. The method includes the steps of contacting anon-halogen metal compound with a particulate sorbent and contacting aninorganic sulfur-containing compound with the particulate sorbent, thesulfur-containing compound comprising a sulfur-containing anion, whereinat least a portion of the sulfur in the sulfur-containing compound hasan oxidation state of equal to or less than +4.

The foregoing method may be subject to refinements, characterizationsand/or additional steps, which may be implemented alone or in anycombination. In one characterization, the non-halogen transition metalcompound is in the form of a solution during the step of contacting thenon-halogen transition metal compound with the particulate sorbent. Inanother characterization, the inorganic sulfur-containing compound is inthe form of a solution during the step of contacting the inorganicsulfur-containing compound with the particulate sorbent. In onerefinement, the non-halogen transition metal compound and the inorganicsulfur-containing compound are in the form of a single solution suchthat the contacting steps are carried out simultaneously.

In another characterization, the sorbent composition is transported to apoint-of-use, and no effective amount of a halogen is added to thesorbent composition before transporting to the point-of-use.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a boiler plant configuration and method for thecapture and sequestration of contaminants from a flue gas stream.

FIG. 2 illustrates a flowsheet for the production of a sorbentcomposition according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

It is an advantage of the sorbent composition disclosed herein that thecomposition may be highly effective for the sequestration of heavymetals, particularly for the sequestration of mercury from a flue gasstream, without the need for a significant concentration of halogens inthe composition. In one embodiment, the present disclosure is directedto a sorbent composition for the capture of contaminants from a gasstream. The sorbent composition includes a particulate sorbent, anon-halogen metal compound comprising a metal cation, and an inorganicsulfur-containing compound comprising a sulfur-containing anion. Atleast a portion of the sulfur in the sulfur-containing compound has anoxidation state (e.g., valence) of equal to or less than +4, e.g., of 0,+2 or −2. As used herein, the term “compound” encompasses moleculargroups having at least two different constituents. By way of example,non-halogen metal compounds do not include elemental metals, andsulfur-containing compounds do not include elemental sulfur (e.g., Ss).

The sorbent composition disclosed herein may be in the form of a powder,i.e., free flowing particles of the particulate sorbent combined withthe non-halogen metal compound and the inorganic sulfur-containingcompound. As is discussed below, the non-halogen metal compound and/orthe inorganic sulfur-containing compound may be in the form of distinctparticulates that are admixed with the particulate sorbent, and/or maybe disposed on (e.g., coated on) the particulate sorbent.

The particulate (e.g., solid) sorbent is selected to have a relativelyhigh porosity and relatively high surface area for favorable adsorptionproperties. For example, the particulate sorbent may be selected fromalumina (e.g., Al2O3), silica (SiO2), silicates includingaluminosilicates, carbonaceous materials, and combinations of thesematerials. In a particular embodiment, the particulate sorbent comprisesa carbonaceous material. Carbonaceous materials may include, but are notlimited to, those that are derived from (e.g., formed from) any type ofcoal, including but not limited to lignite coal, sub-bituminous coal,bituminous coal, and anthracitic coal, charcoal, pitch,polyacrylonitrile (PAN), coconut shells, wood, biomass, and the like.For example, the carbonaceous material may comprise activated carbonthat is derived from one or more of the foregoing materials. Activatedcarbon is a form of carbonaceous material that has a high degree ofmicroporosity and a high surface area. In certain embodiments, thecarbonaceous material is activated carbon that is derived from a coalfeedstock, e.g., a coal-derived activated carbon. That is, the rawmaterial that is processed to form the activated carbon includes coal.In one characterization the carbonaceous material comprises activatedcarbon that is derived from lignite coal. In another characterization,the particulate sorbent comprises powdered activated carbon (PAC) thatis derived from coal. PAC derived from coal may have many advantageousmorphological properties, such as high surface area, high overallporosity and desirable pore size characteristics that are advantageousfor the sequestration (e.g., adsorption) of species such as mercury.

The median average particle size (D50) of the particulate sorbent (e.g.,solid sorbent particulates) may be relatively small, particularly whenthe sorbent composition is engineered for the capture of mercury orother heavy metal contaminants from a flue gas stream, e.g., byinjection of the sorbent composition into the flue gas stream. In onecharacterization, the median average particle size of the particulatesorbent is not greater than about 50 μm, such as not greater than about30 μm, or even not greater than about 25 μm. For the sequestration ofmercury from a flue gas stream by injection of the sorbent composition,it may be desirable to utilize a particulate sorbent having a medianaverage particle size of not greater than about 20 μm, not greater thanabout 15 μm or even not greater than about 12 μm. Very smallparticulates may, however, be difficult to implement. In certainembodiments, the median particle size may be at least about 2 μm, suchat least about 5 μm, such as at least about 6 μm. The median averageparticle size of the particulate sorbent may be measured usingtechniques such as light scattering techniques (e.g., using a SaturnDigiSizer II, available from Micromeritics Instrument Corporation,Norcross, Ga.).

In one characterization, the particulate sorbent (e.g., PAC) has arelatively high total pore volume and a well-controlled distribution ofpores, particularly among the mesopores (i.e., from 20 A to 500 A width)and the micropores (i.e., not greater than 20 A width). Awell-controlled distribution of micropores and mesopores is desirablefor effective removal of mercury from the flue gas stream. While notwishing to be bound by any theory, it is believed that the mesopores arethe predominant structures for capture and transport of the oxidizedmercury species to the micropores, whereas micropores are thepredominate structures for sequestration of the oxidized mercuryspecies.

The total pore volume of the particulate sorbent (sum of microporevolume plus mesopore volume plus macropore volume) may be at least about0.10 cc/g, such as at least 0.20 cc/g, at least about 0.25 cc/g or evenat least about 0.30 cc/g. The micropore volume of the particulatesorbent may be at least about 0.10 cc/g, such as at least about 0.15cc/g. Further, the mesopore volume of the particulate sorbent may be atleast about 0.10 cc/g, such as at least about 0.15 cc/g. In onecharacterization, the ratio of micropore volume to mesopore volume maybe at least about 0.7, such as 0.9, and may be not greater than about1.5. Such levels of micropore volume relative to mesopore volume mayadvantageously enable efficient capture and sequestration of oxidizedmercury species by the particulate sorbent. Pore volumes may be measuredusing gas adsorption techniques (e.g., N2 adsorption) using instrumentssuch as a TriStar II Surface Area Analyzer 3020 or ASAP 2020(Micromeritics Instruments Corporation, Norcross, Ga., USA).

The particulate sorbent may also have a relatively high surface area.For example, the particulate sorbent may have a surface area of at leastabout 350 m²/g, such as at least about 400 m²/g or even at least about500 m²/g. Surface area may be calculated using theBrunauer-Emmett-Teller (BET) theory that models the physical adsorptionof a monolayer of nitrogen gas molecules on a solid surface and servesas the basis for an analysis technique for the measurement of thespecific surface area of a material. BET surface area may be measuredusing the Micromeritics TriStar II 3020 or ASAP 2020 (MicromeriticsInstrument Corporation, Norcross, Ga.).

The sorbent composition also includes a non-halogen metal compound. Anon-halogen metal compound is a metal compound that does not include ahalogen as a constituent of the compound, e.g., compounds that do notinclude fluorine (F), chlorine (Cl), bromine (Br) or iodine (I) as aconstituent. In one characterization, the non-halogen metal compoundincludes a metal selected from the group consisting of iron (Fe), copper(Cu), vanadium (V), manganese (Mn), cobalt (Co), nickel (Ni), and zinc(Zn). The metal compound is selected from those compounds that do notinclude a halogen, e.g., compounds that do not include fluorine (F),chlorine (Cl), bromine (Br) or iodine (I). The metal cation may beselected from the group consisting of a cation of iron (Fe), copper(Cu), nickel (Ni), cobalt (Co), manganese (Mn), vanadium (V) and zinc(Zn). Non-halogen metal compounds including iron and/or copper may beparticularly advantageous for many applications. In any case, the metalcation in the non-halogen metal compound may have an oxidation state(e.g., a valence) of +2 or +3, and in certain embodiments the metalcation in the non-halogen metal compound has an oxidation state of +3.

The non-halogen metal compound may advantageously be selected fromcompounds that include an oxyanion, such as a sulfur oxyanion or anitrogen oxyanion. In certain embodiments, the non-halogen metalcompound comprises a metal selected from iron, copper, vanadium,manganese, cobalt, nickel, and zinc, and a sulfate anion (SOi-), or ametal selected from iron, copper, vanadium, manganese, cobalt, nickel,and zinc, and a nitrate anion (NQ3-). Examples of such compoundsinclude, but are not limited to, those listed in Table I.

TABLE I Non-Halogen Metal Compounds Compound Name Formula Iron (Ill)sulfate Fe2(SQ4)3 Iron (II) sulfate FeSO4 Copper (II) sulfate CuSO4Manganese (Ill) sulfate Mn2(SQ4)3 Nickel (II) sulfate NiSO4 Nickel (Ill)sulfate Ni2(SQ4)3 Ferrous ammonium sulfate (NH4)2Fe(SQ4)2 Iron (II)nitrate Fe(NQ3)2 Copper (II) nitrate Cu(NQ3)2 Nickel (II) nitrateNi(NQ3)2 Iron (Ill) nitrate Fe(NQ3)3 Manganese (Ill) nitrate Mn(NQ3)3Nickel (Ill) nitrate Ni(NQ3)3

In one particular embodiment, the non-halogen metal compound may beselected from compounds including iron or copper with a sulfate anion,such as Fe2(SQ4)3, FeSO4, CuSQ4 and combinations thereof. It will beappreciated that the non-halogen metal compounds may also be in ahydrated form, e.g., Fe2(SQ4)3.7H2O, and reference herein to any suchnon-halogen metal compound includes hydrated forms of the compound.

The sorbent composition also includes an inorganic sulfur-containingcompound that includes a sulfur-containing anion, where at least aportion of the sulfur in the sulfur-containing compound has an oxidationstate (e.g., a valence) of equal to or less than +4, e.g., an oxidationstate of 0, +2 or −2. For example, the sulfur-containing anion may beselected from the group consisting of thiocyanate (SCN)¹—, thiosulfate(S2O3)²—, tetrathionate (S4O6)²- and polythionate (SO3-Sn—SO3)²-.Examples of such compounds include, but are not limited to, thecompounds listed in Table II.

TABLE II Sulfur-Containing Compounds Compound Name Formula S OxidationState(s) Sodium thiocyanate NaSCN −2 Ammonium thiocyanate NH4SCN −2Potassium thiocyanate KSCN −2 Calcium thiocyanate Ca(SCN)2 −2 Sodiumthiosulfate Na2S2Q3 −2, +6 Ammonium thiosulfate (NH4)2S2Q3 −2, +6Potassium thiosulfate K2S2Q3 −2, +6 Calcium thiosulfate CaS2Q3 −2, +6Sodium tetrathionate Na2S4Q5   0, +5

In one particular embodiment, the sulfur-containing anion isthiocyanate. For example, the sulfur-containing compound may be selectedfrom sodium thiocyanate and ammonium thiocyanate. In another particularembodiment, the sulfur-containing anion is thiosulfate (S2Q3)²-. Forexample, the sulfur-containing compound may be selected from sodiumthiosulfate (Na2S2Q3) and ammonium thiosulfate ((NH4)2S2O3).

The sorbent composition comprises at least the three foregoingcomponents, namely a particulate sorbent, a non-halogen metal compound,and an inorganic sulfur-containing compound. The components are combinedin the appropriate concentrations and/or ratios to provide favorableadsorption properties, e.g., favorable sequestration of mercury from aflue gas stream. In one characterization, the concentration of the metalcation (i.e., from the non-halogen metal compound) is at least about 0.1wt. % of the sorbent composition, such as at least about 0.25 wt. %,such as at least about 0.5 wt. %, or even at least about 1.0 wt. % ofthe sorbent composition. In another characterization, the concentrationof the metal cation is not greater than about 20 wt. % of the sorbentcomposition, such as not greater than about 15 wt. %, such as notgreater than about 10 wt. %, or even not greater than about 5 wt. % ofthe sorbent composition.

In another embodiment, the concentration of the inorganicsulfur-containing compound is at least about 0.05 wt. % of the sorbentcomposition, such as at least about 0.1 wt. %, such as at least about1.0 wt. %, or even at least about 2.0 wt. % of the sorbent composition.In another characterization, the concentration of the inorganicsulfur-containing compound is not greater than about 30 wt. % of thesorbent composition, such as not greater than about 25 wt. %, such asnot greater than about 15 wt. %, such as not greater than about 10 wt.%, or even not greater than about 5 wt. % of the sorbent composition.

In accordance with the foregoing embodiments, the concentration of theparticulate sorbent may be at least about 50 wt. % of the of the sorbentcomposition, such as at least about 60 wt. %, such as at least about 70wt. %, such as at least about 80 wt. %, such as at least about 90 wt. %,or even at least about 95 wt. % of the sorbent composition. Typically,the concentration of the particulate sorbent will be not greater thanabout 99.5 wt. % of the sorbent composition, such as not greater thanabout 99 wt. % of the sorbent composition.

The sorbent composition disclosed herein may include other additives inaddition to the non-halogen metal compound and the inorganicsulfur-containing compound according to the present disclosure. However,as is discussed above, it is preferred that no effective amount of ahalogen species is added to the sorbent composition.

As is discussed above, it is an advantage of the sorbent compositionsdisclosed herein that the compositions may be highly effective for thesequestration of heavy metals, particularly for the sequestration ofmercury from a flue gas stream, without the need for a significantconcentration of halogens to oxidize the mercury. In accordance with oneembodiment of the present disclosure, the sorbent composition comprisenot greater than about 1 wt. % halogens, such as not greater than about0.5 wt. % halogens, or even not greater than about 0.1 wt. % halogens.In another embodiment, the sorbent composition may include substantiallyno added halogens, i.e., no concentration of halogens beyond thehalogens that are naturally present in the particulate sorbent. Forexample, when the particulate sorbent in derived from lignite coal, theparticulate sorbent may comprise up to about 0.08 wt. % native halogens,such as about 0.02 wt. % of native halogens, i.e., halogens thatoriginated from the lignite coal, typically comprising Cl and/or F. Inother embodiments, the sorbent composition comprises substantially nohalogens.

Another embodiment of the present disclosure is directed to a method forthe manufacture of a sorbent composition, i.e., a sorbent compositiondisclosed above. The method includes the steps of contacting theparticulate sorbent with the non-halogen metal compound and with theinorganic sulfur-containing compound comprising a sulfur-containinganion, wherein at least a portion of the sulfur in the sulfur-containingcompound has an oxidation state of less than +4, e.g., of 0, +2 or −2,with the particulate sorbent. The contacting step can include, forexample, mixing (e.g., dry blending) the constituents to form ahomogeneous mixture of the individual constituents.

In one characterization, the non-halogen metal compound is in solution(e.g., in an aqueous solution) during the step of contacting thenon-halogen metal compound with the particulate sorbent. In anothercharacterization, the inorganic sulfur-containing compound is insolution (e.g., an aqueous solution) during the step of contacting theinorganic sulfur-containing compound with the particulate sorbent. Forexample, the non-halogen metal compound and the inorganicsulfur-containing compound may be included in a single solution suchthat the contacting steps are carried out simultaneously. By way ofexample, such solution(s) may be sprayed onto the particulate sorbent orthe particulate sorbent may be immersed in the solution(s) for a periodof time. When the non-halogen metal compound and the inorganicsulfur-containing compound are contacted with the particulate sorbent inthe form of a solution and are subsequently dried, the compounds mayform a coating on the surface of the particulate sorbent.

FIG. 1 is a flow sheet that illustrates an exemplary method for themanufacture of a sorbent composition in accordance with one embodiment,i.e., for the manufacture of a sorbent composition according to thepresent disclosure. The manufacturing process may begin with acarbonaceous feedstock 110 such as coal, e.g., lignite coal, anthraciticcoal, bituminous coal or sub-bituminous coal. The feedstock 110 issubjected to an elevated temperature and one or more oxidizing gasesunder exothermic conditions for a period of time to increase surfacearea, create porosity, alter surface chemistry, and expose and exfoliatenative minerals previously contained within feedstock. The specificsteps in the process illustrated in FIG. 1 include: (1) dehydration 112,where the feedstock is heated to remove free and bound water, typicallyoccurring at temperatures ranging from 100° C. to 150° C.; (2)devolatilization 114, where free and weakly bound volatile organicconstituents are removed, typically occurring at temperatures above 150°C.; (3) carbonization 116, where non-carbon elements continue to beremoved and elemental (fixed) carbon is concentrated and transformedinto random amorphous structures, typically occurring at temperaturesaround 350° C. to 800° C.; and (4) activation 118, where steam, air oranother oxidizing agent is added and pores are developed, typicallyoccurring at temperatures above 800° C. The manufacturing process may becarried out, for example, in a multi-hearth or rotary furnace. Themanufacturing process is not discrete and steps can overlap and usevarious temperatures, gases and residence times within the ranges ofeach step to promote desired surface chemistry and physicalcharacteristics of the manufactured product.

After activation 118, the thermally treated product (e.g., granularactivated carbon) may be subjected to a comminution step 122 to reducethe particle size (e.g., the median particle size) of the product (e.g.,to form powdered activated carbon). Comminution 122 may occur, forexample, in a mill such as a roll mill, jet mill or other like device.Comminution 122 may be carried out for a time sufficient to reduce themedian (D50) particle size of the thermally treated product, e.g., tonot greater than about 100 such as not greater than about 75 such as notgreater than about 50 such as not greater than about 30 such as notgreater than about 20 μm or even not greater than about 15 μm.

In the event that manufacturing conditions result in a greater number ofcarbonaceous particles that have a very fine size than is desired,classification 124 may be carried out to remove such very fine particlesfrom the larger carbonaceous particles. For example, classification 124may be carried out using an air classifier, screen/mesh classification(e.g., vibrating screens) or centrifugation. Smaller particles may alsobe agglomerated to reduce the concentration of fine particles.

One or more additives may be contacted with the activated carbon duringmanufacture, including but not limited to the non-halogen metal compoundand the inorganic sulfur-containing compound according to the presentdisclosure. For example, the additives may be in the form of one or moresolutions that may be contacted with (e.g., sprayed onto) the sorbentprior to 120A or after 1208 comminution 122. In this regard, thenon-halogen metal compound and the inorganic sulfur-containing compoundmay be coated on and/or impregnated into the solid sorbent.Alternatively, or in addition, particulates (e.g., dry particulates) ofthose additives may be admixed with the sorbent prior to 120A and/orafter 1208 comminution 122.

In another characterization, the method includes facilitating thetransport of the sorbent composition to a point-of-use, wherein nohalogen species (e.g., no effective amount of a halogen species toenhance oxidation of mercury) is added to the sorbent composition beforebeing transported to the point-of-use.

The present disclosure is also related to a method for the treatment ofa gas stream to capture contaminants from the gas stream. The methodincludes the steps of contacting the gas stream with at least aparticulate sorbent, a non-halogen metal compound as described above,and with an inorganic sulfur-containing compound as is describe above.These components may be contacted with the gas stream by injecting asorbent composition into the flue gas stream, where the sorbentcomposition includes each of the three components, as is describedabove. That is, the sorbent composition that is contacted with the gasstream (e.g., is injected into the gas stream) may include a particulatesorbent, a non-halogen metal compound comprising a metal cation selectedfrom iron, copper, vanadium, manganese, cobalt, nickel, and zinc, and aninorganic sulfur-containing compound comprising a sulfur-containinganion, where at least a portion of the sulfur in the sulfur-containingcompound has an oxidation state of less than +4, e.g., of 0, +2 or −2.

Alternatively, or additionally, one or more of the components may becontacted with the gas stream as a discrete component, e.g., where thediscrete component is not associated with (e.g., admixed with or coatedonto) another component. For example, the particulate sorbent may becontacted with the gas stream as a discrete component and an admixtureof the non-halogen metal compound and the sulfur-containing compound maybe contacted with the gas stream independent from the particulatesorbent, e.g., at a separate injection point. Alternatively, one of thenon-halogen metal compound or the sulfur-containing compound may beassociated with (e.g., admixed with or coated onto) the particulatesorbent, while the other component is contacted with the gas stream as adiscrete component. In another alternative, each of the three componentsmay be contacted with the gas stream as a discrete component.

The flue gas stream may be a flue gas stream emanating from a boiler.For example, the method may include the use of a coal-fired boilerwherein coal is combusted to generate energy. The combustion of coaltypically generates undesirable contaminants that must be removed fromthe flue gas, including heavy metals such as mercury (Hg). In certainembodiments, the flue gas stream has relatively low concentration ofacid gasses. For example, the flue gas stream may comprise not greaterthan about 5 ppm S03, such as not greater than about 3 ppm S03.

FIG. 2 schematically illustrates a system and method for removal ofmercury from a flue gas stream using sorbent injection to contact thesorbent composition with the flue gas stream. The flue gas stream 212exits a boiler 210 where a feedstock such as coal has been combusted.The flue gas stream 212 as it exits the boiler 210 typically has atemperature of from about 600° F. to about 900° F. As illustrated inFIG. 2 , the flue gas stream 212 may then proceed to an air preheaterunit 216 where the temperature of the flue gas stream 212 is reduced,generally to about 325° F. However, if the air preheater unit 212 is notoperating efficiently, or there is no air preheater unit, as isfrequently the case at industrial boiler sites, the flue gas streamtemperature may exceed 325° F., e.g., being at or above about 340° F.,being even as high as about 600° F. at the entrance to the particulatematter collection device.

After the air preheater unit 216, the flue gas stream 212 may beintroduced to a particulate matter collection device 218 such as anelectrostatic precipitator (ESP) or a fabric filter bag house whichremoves particulate matter from the flue gas stream 212, before exitingout a stack 224. For example, a cold-side (i.e., after the air preheaterunit) electrostatic precipitator can be used. It will be appreciated bythose skilled in the art that the plant may include other devices notillustrated in FIG. 2 , such as a selective catalytic reduction unit(SCR) and the like, and may have numerous other configurations.

In order to capture mercury from the flue gas stream 212, a sorbentcomposition (e.g., comprising the three components as disclosed above)may be introduced to (e.g., injected into) and contacted with the fluegas stream 212 either before 214A or after 2148 the air preheater unit216, but before the particulate matter collection device 118 which willremove it from the flue gas stream 212. As is disclosed above, one ormore of the components may be introduced into the flue gas stream 212 asa discrete component. In this characterization, any one or all threecomponents may be introduced before 214A the air preheater unit 216 orafter 2148 the air preheater unit 216. Merely by way of example, thenon-halogen metal compound and the sulfur-containing compound may beinjected into the flue gas stream 212 before 214A the air preheater unit216 (e.g., discretely or as an admixture), and the particulate sorbentmay be injected into the flue gas stream 212 after 2148 the airpreheater unit 216.

EXAMPLES Example 1

A first baseline sample (Sample B1) is obtained for comparison to thesorbent compositions disclosed herein. Sample B1 is a commercial sorbentthat is sold under the trademark FastPAC® by ADA Carbon Solutions(Littleton, Colo.). Sample B1 comprises a powdered activated carbon(PAC) that is derived from a lignite coal feedstock, and has a medianparticle size (D50) of about 13 μm.

Example 2

A sample according to the present disclosure (Sample D2) is formed bymodifying Sample B1 with ferric sulfate (Fe2(SQ4)3) and sodiumthiocyanate (NaSCN). Sample D2 is prepared by spraying a solutioncontaining both ferric sulfate and sodium thiocyanate onto about 50grams of Sample B1 over a period of about 10 minutes while the PAC isbeing mixed in a fluidized mixing vessel. Sufficient solution is sprayedonto the PAC so that about 1 wt. % of iron and about 4.3 wt. % of sodiumthiocyanate are deposited onto the PAC after drying.

Example 3

A further sample according to the present disclosure (Sample D3) isformed by modifying Sample B1 with ferric sulfate (Fe2(SQ4)3) andammonium thiocyanate (NH4SCN). Sample D3 is prepared by spraying asolution containing ferric sulfate onto about 50 grams of Sample 1 overa period of about 10 minutes while the PAC is being mixed in a fluidizedmixing vessel. The addition of ferric sulfate is followed by spraying asolution containing ammonium thiocyanate onto the PAC while the PAC tobe mixed in a fluidized mixing vessel. A sufficient amount of thesolutions is sprayed onto the PAC in sequence so that about 2 wt. % ironand about 3 wt. % ammonium thiocyanate are deposited onto the PAC afterdrying.

Example 4

A further sample according to the present disclosure (Sample D4) isformed by modifying Sample B1 with ferrous sulfate (FeSO4) and sodiumthiocyanate (NaSCN). Sample D4 is prepared by spraying a solutioncontaining both ferrous sulfate and sodium thiocyanate onto about 50grams of Sample B1 over a period of about 10 minutes while the PAC isbeing mixed in a fluidized mixing vessel. Sufficient solution is sprayedonto the PAC so that about 1.1 wt. % iron and about 3.3 wt. % sodiumthiocyanate are deposited onto the PAC after drying.

Example 5

A further sample according to the present disclosure (Sample D5) isformed by modifying Sample B1 with copper sulfate (CuSO4) and sodiumthiocyanate (NaSCN). Sample D5 is prepared by spraying a solutioncontaining both copper sulfate and sodium thiocyanate onto about 50grams of Sample B1 over a period of about 10 minutes while the PAC isbeing mixed in a fluidized mixing vessel. Sufficient solution is sprayedonto the PAC so that about 0.5 wt. % copper and about 2.2 wt. % sodiumthiocyanate are deposited onto the PAC after drying.

Example 6

A comparative sample (Sample C6) is formed by modifying Sample B1 withferric sulfate (Fe2(SQ4)3). Sample C6 is prepared by spraying a solutioncontaining ferric sulfate onto about 50 grams of Sample B1 over a periodof about 10 minutes while the PAC is being mixed in a fluidized mixingvessel. Sufficient solution is sprayed onto the PAC so that about 1 wt.% iron is deposited onto the PAC after drying.

Example 7

A comparative sample (Sample C7) is formed by modifying Sample B1 withferrous sulfate (FeSO4). Sample C7 is prepared by spraying a solutioncontaining ferrous sulfate onto about 50 grams of Sample B1 over aperiod of about 10 minutes while the PAC is being mixed in a fluidizedmixing vessel. Sufficient solution is sprayed onto the PAC so that about1.6 wt. % iron is deposited onto the PAC after drying.

Example 8

A comparative sample (Sample C8) is formed by modifying Sample B1 withcopper sulfate (CuSO4). Sample C8 is prepared by spraying a solutioncontaining copper sulfate onto about 50 grams of Sample 1 over a periodof about 10 minutes while the PAC is being mixed in a fluidized mixingvessel. Sufficient solution is sprayed onto the PAC so that 1 wt. % ofcopper is deposited onto the PAC after drying.

Example 9

A comparative sample (Sample C9) is formed by modifying Sample B1 withsodium thiocyanate (NaSCN). Sample C9 is prepared by spraying a solutioncontaining sodium thiocyanate onto about 50 grams of Sample B1 over aperiod of about 10 minutes while the PAC is being mixed in a fluidizedmixing vessel. Sufficient solution is sprayed onto the PAC so that about5 wt. % of sodium thiocyanate is deposited onto the PAC after drying.

Example 10

A comparative sample (Sample C10) is formed by modifying Sample B1 withphosphoric acid (H3PQ4) and ammonium thiocyanate (NH4SCN). Sample C10 isprepared by spraying a phosphoric acid solution and solution containingammonium thiocyanate onto about 50 grams of Sample B1, in sequence, overa period of about 10 minutes while the PAC is being mixed in a fluidizedmixing vessel. Sufficient solution is sprayed onto the PAC so that about5 wt. % of ammonium thiocyanate is deposited onto the PAC after drying.

DMI Test

The ability to capture mercury may be measured by a dynamic mercuryindex (DMI) test developed by ADA Carbon Solutions, LLC and thatmeasures mercury (Hg) captured in micro-grams of Hg per gram of sorbentcomposition Gig Hg/g sorbent composition) in a flowing mercury-laden gasstream at elevated temperatures. An increase in, or higher DMI, or μgHg/g carbon (μg/g) captured, is an indication of a higher mercurycapture efficiency of a sorbent. The DMI test simulates conditions in acoal burning facility's flue gas stream. The test system includes apreheater, sorbent feed, mercury feed, and reaction chamber. The mercuryis fed into a reactor chamber along with the sorbent composition,wherein they are entrained. Uncaptured mercury is analyzed and DMIcalculated. Temperature of the entrained mercury and sorbent is kept atabout 325° F. (163° C.). Air entrainment and injection rates of betweenabout 1 and about 5 lb./MMacf (pounds sorbent per one million actualcubic feet) are maintained such that residence time of the sorbent inthe reaction chamber is about one second to simulate electricalgeneration unit (EGU) facility conditions. The initial mercuryconcentration in the system is approximately 10 μg/m³.

Each of the foregoing samples is measured to determine its DMI, and theresults are listed in Table III.

TABLE III Mercury Capture Performance Sulfur- DMI Containing (ug Hg/gsorbent Sample Metal Wt. % Anion Wt. % composition) B1 N/A N/A N/A N/A20 D2 Fe (Ill) 1.0 NaSCN 4.3 321 D3 Fe (Ill) 2.0 NH4SCN 3.0 253 D4 Fe(II) 1.1 NaSCN 3.3 299 D5 Cu (II) 0.5 NaSCN 2.2 222 C6 Fe (III) 1.0 N/AN/A 47 C7 Fe (II) 1.6 N/A N/A 110 cs Cu (II) 1.0 N/A N/A 152 C9 — —NaSCN 5.0 38 C10 — — NH4SCN 5.0 64

On their own, sulfur-containing compounds combined with a base sorbent(Samples C9 and C10) give relatively low mercury removal performance, inthe range of 38-64 ug Hg/g sorbent. Similarly, non-halogen metalcompounds alone with a base sorbent (Samples C6 to C8) remove mercury inthe range of 47-152 ug Hg/g sorbent. There is synergism when the twocomponents are incorporated together in the sorbent, and even with loweradditive levels, and performance up to around 222-321 ug Hg/g sorbentcan be achieved. See Samples D2 to D5. The combination of the specifiedmetals and a low oxidation state sulfur compounds can give mercuryremoval performance at least equivalent to standard halogenatedactivated carbons.

While not wishing to be bound to any particular theory, this synergy isbelieved to be caused by the selected metal activating the sulfurcompound so that the sulfur compound is more reactive to mercury in theflue gas. For the case of thiocyanate, the metal cation attracts thenitrogen, effectively pulling electron density away from the sulfurcompound. Thus, the sulfur atom is more reactive to mercury in the fluegas. Alternatively, the mechanism may involve two steps where the metalfirst oxidizes elemental mercury, and the oxidized mercury issequestered on the sorbent by the low oxidation state sulfur compound.

While various embodiments of a sorbent composition and a method for thetreatment of a flue gas stream have been described in detail, it isapparent that modifications and adaptations of those embodiments willoccur to those skilled in the art. However, it is to be expresslyunderstood that such modifications and adaptations are within the spiritand scope of the present disclosure.

1. A method for the treatment of a gas stream to capture contaminantsfrom the gas stream, comprising the steps of: contacting the gas streamwith a particulate sorbent to disperse the particulate sorbent withinthe gas stream; contacting the gas stream with a non-halogen metalcompound comprising a metal cation; contacting the gas stream with aninorganic sulfur-containing compound, wherein at least a portion of thesulfur in the sulfur-containing compound has an oxidation state of equalto or less than +4; and separating the particulate sorbent from the gasstream.
 2. The method recited in claim 1, wherein each of the contactingsteps are carried out by contacting the gas stream with a sorbentcomposition comprising the particulate sorbent, the non-halogen metalcompound and the inorganic sulfur-containing compound.
 3. The methodrecited in claim 2, wherein the sorbent composition comprises notgreater than about 0.5 wt. % halogens.
 4. The method recited in claim 2,wherein the sorbent composition comprises not greater than about 0.1 wt.% halogens.
 5. The method recited in claim 2, wherein the sorbentcomposition comprises substantially no halogens.
 6. The method recitedin claim 2, wherein the sorbent composition is in the form offree-flowing particulates, and wherein the contacting steps compriseinjecting the free-flowing sorbent composition particulates into the gasstream.
 7. The method recited in claim 1, wherein the step of contactingthe gas stream with a particulate sorbent comprises injecting theparticulate sorbent into the gas stream.
 8. The method recited in claim7, wherein the step of contacting the gas stream with the inorganicsulfur-containing compound comprises injecting the inorganicsulfur-containing compound into the gas stream.
 9. The method recited inclaim 8, wherein the inorganic sulfur-containing compound is injectedinto the gas stream as a discrete component.
 10. The method recitedclaim 7, wherein the step of contacting the gas stream with thenon-halogen metal compound comprises injecting the non-halogen metalcompound into the gas stream.
 11. The method recited in claim 10,wherein the non-halogen metal compound is injected into the gas streamas a discrete component.
 12. The method recited in claim 1, wherein thegas stream is a gas stream emanating from a boiler.
 13. The methodrecited in claim 1, wherein the gas stream is a gas stream emanatingfrom a coal-fired boiler.
 14. The method recited in claim 1, wherein thecontaminants comprise mercury.
 15. A method for the treatment of a gasstream to capture contaminants from the gas stream, comprising the stepsof: receiving the gas stream comprising mercury; contacting a sorbentcomposition with the gas stream, wherein the sorbent compositioncomprises a particulate sorbent, a non-halogen metal compound, and asulfur containing compound; and separating at least a portion of themercury from the gas stream based at least in part on the sorbentcomposition.
 16. The method recited in claim 15, wherein the step ofcontacting the gas stream with the sorbent composition comprisesinjecting the sorbent composition into the gas stream.
 17. The methodrecited in claim 15, wherein the particulate sorbent, the non-halogenmetal compound, and the sulfur containing compound of the sorbentcomposition are discrete components.
 18. A method for the treatment of agas stream to capture mercury from the gas stream, comprising the stepsof: receiving, from a boiler, the gas stream comprising mercury;contacting a sorbent composition with the gas stream, wherein thesorbent composition comprises a particulate sorbent, a non-halogen metalcompound, and a sulfur-containing compound, wherein the sorbentcomposition is contacted with the gas stream before or after the gasstream passes through a preheater unit; and separating at least aportion of the mercury from the gas stream based at least in part on thesorbent composition.
 19. The method recited in claim 18, wherein one ormore of the particulate sorbent, the non-halogen metal compound, and thesulfur-containing compound of the sorbent composition is contacted withthe gas stream before passing the gas stream through the preheater unit,after passing the gas stream through the preheater unit, or acombination thereof.
 20. The method recited in claim 18, wherein thestep of separating at least the portion of the mercury from the gascomprises passing the gas stream through a particulate collection devicethat separates the sorbent composition from the gas stream.